Quick fence

ABSTRACT

A modular fence panel and assembly. The modular fence panel has upper and lower channels. Each channel has through apertures that are equally spaced apart on the channel. Each aperture has a locking cap inserted therein for engaging the vertical picket. The locking cap, once inserted into the aperture, locks itself to the aperture. The picket, which has a spring clip inside, locks itself to the locking cap after the picket is inserted into the aperture on the channel. The spring clip prevents the picket from being removed from the channel. During assembly, the channels are first connected to vertical posts at both ends, through a pivoting connector, and then the pickets are inserted through the aligned apertures on the channels. The pivoting connector allows movements in both vertical and horizontal directions to accommodate different requirements for the fence assembly.

FIELD OF THE INVENTION

The present invention relates generally to the field of fences and moreparticularly relates to modular fence panels and assemblies that can bequickly assembled.

ART BACKGROUND

Wrought iron fences are well known in the home, gardening and commercialfield. In addition to serving as a security barrier for an owner'sproperty, the fences can be used as protective fencing around swimmingpools and gardens. The conventional wrought iron fences are formed bywelding metal rods to upper and lower rails to form panels. Panels arejoined by welding or bolting to upright posts.

While the fences are sturdy for their intended purposes, they stillpresent some problems. One problem is that the welded areas aresusceptible to rusting, even with a painted cover, or with galvanizedcomponents. Rusting, or oxidation, eventually causes the welded area tolose its structural integrity. Also, as more and more homeowners take updoing their own home improvements, stores such as Home Depot would liketo carry fences that are modular, and can be easily assembled by theircustomers without requiring any welding. Their rationale is two-fold:The modularity of the fence panels allows the stores to minimize thedifferent sizes of panels they have to carry. Also, the ease of assemblyallows the stores to reach a broader customer base, such as thosehomeowners who do their projects on weekends.

To form a complete barrier assembly, conventional fence panels need tobe joined to the vertical posts at both ends. However, such assembly isquite limiting, because it typically is achieved by using a straightconnector between the panel and the post. Such straight connector offersvery little, if any, range of movement or adjustment between the postand the fence panel.

Therefore, it is desirable to provide a picket fence panel and assemblythat is quick to assemble at the job site, without requiring anywelding. It is also desirable to provide a picket fence panel andcomponents that can provide a variety of height and angular arrangementsfor the users based on the requirements of the location.

SUMMARY OF THE INVENTION

A modular fence panel and assembly is disclosed. The modular fence panelhas upper and lower channels. Each channel has through apertures thatare equally spaced apart on the channel. Each aperture has a locking capinserted therein for engaging the vertical picket. The locking cap, onceinserted into the aperture, locks itself to the aperture. The picket,which has a spring clip inside, locks itself to the locking cap afterthe picket is inserted into the aperture on the channel. The spring clipprevents the picket from being removed from the channel. Duringassembly, the channels are first connected to vertical posts at bothends, through a pivoting connector. The pivoting connector allowsmovements in both vertical and horizontal directions to accommodatedifferent requirements for the fence assembly. With the channels inplace and apertures aligned, the pickets are then inserted through thealigned apertures on the channels.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is a simplified diagram of an exemplary modular picket fencepanel 10 in accordance with the present invention.

FIG. 2 is a simplified diagram of an exemplary modular picket fencepanel 10 to be connected to the vertical posts 20 by connectors 22 inaccordance with the present invention.

FIG. 3(a) is a simplified diagram showing a locking cap 32 to beinserted into the through aperture 15 on the channel 14. FIGS. 3(b)-(d)show an exemplary locking cap in perspective, front and side plan views,respectively.

FIG. 4(a) is a simplified diagram showing a vertical picket 12 beinginserted into the locking cap 32 in the aperture 15 of the channel 14.FIGS. 4(b) and (c) show a V-shaped spring clip and a flattened V-shapedspring clip, respectively.

FIG. 5(a) shows a pivoting connector 22, which can engage the verticalpost 20 in different orientations. FIG. 5(b) shows the pivotingconnector 22 in more detail.

FIG. 6 further illustrates the pivoting connector 22.

FIG. 7 is a simplified diagram showing the fence panels 10 beingconnected to the post 20 through the use of the pivoting connector 22.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A modular fence panel and fence assembly is disclosed. Although specificembodiments of the present invention is described with reference to thedrawings, it should be understood that such embodiments are merelyillustrative of but a small number of the many possible specificembodiments which can represent applications of the teaching of thepresent invention. Various changes and modifications obvious to oneskilled in the art to which the present invention pertains are deemed tobe within the spirit, scope and contemplation of the present inventionas further defined in the appended claims.

Briefly described, the present invention is a modular picket fencepanel, which can be easily assembled without the use of welding, screws,rivets or fasteners. In one embodiment of the present invention, themodular picket fence panel 10 may be assembled with a pair of horizontalupper channel 14 and horizontal lower channel 16, and several vertical,and spaced-apart pickets 12 as shown in FIG. 1. The modular picket fencepanel 10 are attached to vertical end posts 20 at both ends, by usingconnectors such as the pivoting connectors 22, as shown in FIG. 2. Ascan be understood, multiple modular picket fences with their end posts20 can be assembled into different arrangements according to therequirements, such as the shape and elevation, of the landscape orterritory, as illustrated in FIG. 7. Preferably, the channels 14, 16 arefirst connected to the end posts 20, 22 and then each picket 12 isinserted through the aligned apertures on the channels 14, 16. As such,a user need not have the panel 10 already assembled and transported tothe job site, which may require the use of a full-size pickup truck. Inthe unassembled state, the whole set of components, i.e. pickets,channels, posts and connectors, can be easily carried by a consumer'ssedan or small pickup truck.

Referring to FIG. 1, a modular picket fence panel 10 in a basicembodiment is shown. The upper channel 14 and lower channel 16 arepreferably identical. This feature makes it easy to manufacture andalign, since the dimensions and specifications are the same. Each of theupper channel 14 and lower channel 16 has several apertures 15, 17,which are longitudinally equally spaced apart, for receiving the pickets12. The pickets 12 are preferably made of solid steel-based material,hot-dip galvanized in zinc, with baked powder coating. The pickets 12preferably have a four-sided cross section. The apertures 15, 17, are ofthe shape and size compatible with the cross-sectional shape and size ofthe pickets 12, such that the pickets may be inserted through theapertures 15, 17, preferably through a locking cap 32, as furtherillustrated in FIGS. 3(a)-(d). Both ends of the upper and lower channelsalso have apertures 13, 19 on the side of the channel and located atopposite ends, which are for engaging the channels to the posts 20.

It should be noted that the pickets may have a cross-sectional shapethat is other than the typical four-sided shape. More specifically, thepickets may have a round, or oval, cross section, while the aperture 15on the channel is also of a round shape. Alternately, a four-sidedpicket may work with a round aperture, provided that the locking cap 32acts as an interface with a four-sided interior for the picket, and around external shape for the aperture. With the use of the locking cap,the shapes of the pickets can take on any shape, and so can the aperture15 on the channel. As such, more flexibility is offered to themanufactures and more selection is provided to the customers.

Since both the basic structures of the upper channel and lower channelare identical, only the upper channel 14 is further described hereinbelow for illustrative purposes. Referring to FIGS. 3(a)-(d), a lock cap32 is shown to be ready for insertion and placement into the aperture 15on the channel 14. The locking cap 32 is preferably made of reinforcednylon material, with two sloped one-way locks 33 on opposite sidewallsand at least one aperture 34 on the sidewall (two apertures are shown infathom lines in FIG. 3(d)). The top rim of the locking cap 32 has aprojection 35, or flange, which serves as a stopper for the locking cap32, so that the locking cap 32 cannot be pushed further, as theprojection 35 will abut the top channel surface. The sloped one-waylocks 33 are sized such that they can be slightly compressed inward asthe locking cap 32 is inserted into the aperture 15 on the channel.After the locking cap 32 is fully inserted into the aperture 15, thesloped one-way locks 33, due to their inherent elasticity, spring backto their normal position, thus preventing the locking cap 32 from beingremoved from the aperture. The aperture 34, or receptacle, on thelocking cap 32 is for engaging the picket 12 to the locking cap 32, aswill be described below.

FIG. 4(a) shows the picket 12 ready to be inserted into the aperture 15of the channel 14 through the locking cap 32, which is already in theaperture 15. To ensure that the picket 12 is locked in position afterinsertion, a spring clip 42 is used, as further illustrated in FIG. 4(b)and (c). The spring clip 42, which is preferably a V-shaped clip or aflattened V-shaped clip as shown in FIG. 4(b) and (c), respectively, isplaced inside the picket 12 at a position where the picket 12 intersectsthe upper channel 15. The flattened V-shaped clip, due to its increasedwidth at the flattened segment, offers a better fit to the inside of thehollow picket 12. A better fit thus contributes to more stability of thespring clip inside the picket 12. The picket 12 preferably does not needto use a spring clip 42 at its lower end to lock to the lower channel,so that the insertion of the picket can be done much faster, andsimpler, from the upper channel to the lower channel. The button 43 onthe spring clip 42, when compressed by the user during insertion of thepicket into the locking cap, will spring back to its normal position toengage the receptacle 34 of the locking cap 32. Once engaged, thestrength of the spring clip 42 keeps the picket 12 in position,preventing its movement in both directions. Also, since the receptacle34 of the locking cap 32 is inside the channel, there is no accesspossible to the button 43 from the outside. As such, the picket 12, onceinserted and the button locked to the receptacle 34, cannot be removedfrom the channels.

Reference is now to FIGS. 5 and 6. After the modular fence panel 12 isassembled, it can be connected to vertical posts, which are fixed to theground. A vertical post 20 may use a conventional straight connector fora level or right-angled arrangement. However, such conventional straightconnector is quite limited. Alternately, a pivoting connector 22 inaccordance with the present invention can be used for an elevated orangled arrangement to engage the modular fence panel 12, as shown inFIG. 5(a) and (b). The pivoting connector 22 has a closed bracket 54 toembrace the post 20 and a open, U-shaped bracket 50 to engage thechannel of the fence. The hinge 56 between the closed bracket 54 and theopen bracket 50 allows the connector 22 to pivot in the horizontaldirection, or X-axis. The slot 57 on the open bracket 50 allows thechannel to adjust in the vertical direction, or Y-axis. In contrast tothe conventional straight connector, the two-degree of movement allowsthe users to accommodate various elevation or shape requirements of thefence assembly.

To fully take advantage of the fact that the pickets are secured only toone, e.g. upper, channel, the fence assembly in accordance with thepresent invention may be assembled in a drastically different way fromthe conventional method. Since only the upper channel is secured to thepickets through the use of the locking caps, while the lower channel isnot, a consumer can easily first connect both channels to the verticalposts at their two ends. Then, with the channels in place, the consumercan easily insert one picket at a time through the apertures on eachchannel. In contrast, a conventional fence is assembled by inserting thepickets first through the channels, which are then connected to theposts. The versatility now offered by the present invention allows thefences to be easily transported in their un-assembled componentcondition, instead of being transported as the assembled panels to thejob site.

FIG. 7 shows two fence panels 10, connecting to the post 20 through thepivoting connector 22. As can be appreciated, the angle between thepanels 10 may be changed by the hinge 56 and their respective elevationmay be changed by the slots 57. As previously noted, however, the orderin which the whole fence assemblies are assembled preferably begins withconnecting the channels to the posts. The pickets are then insertedthough the aligned channels.

The present invention has been described in a considerable detail inorder to comply with the patent laws by providing full public disclosureof at least one of its forms. However, such detailed description is notintended in any way to limit the broad features or principles of thepresent invention, or the scope of the patent to be granted. Therefore,the invention is to be limited only by the scope of the appended claims.

1. A modular fence panel, comprising: lower and upper channels, eachchannel having a plurality of equally spaced apart through aperturesalong the length of each channel, said through apertures on said lowerchannel and said upper channel being aligned; a locking cap insertedinto each of said through apertures on said lower and upper channels,said locking cap comprising: a sloped lock, disposed to irreversiblyengage the inside of said through aperture upon insertion into saidaperture of said channels; a receptacle on the outside surface of saidlocking cap; a plurality of vertically disposed hollow pickets arrangedin mutually parallel relationship there-between, each of said picketsextending through said locking cap in said through aperture on saidchannel, each of said picket comprising: a spring clip longitudinallyinserted into the inside of each picket at a predetermined location suchthat said spring clip locks into said receptacle on said upper channel.2. The modular fence panel of claim 1, further comprising: a pair ofvertical posts at both ends of said upper and lower channels; aconnector, disposed to join the ends of each of said channels to saidposts.
 3. The modular fence panel of claim 2, wherein said connector isa pivoting connector, comprising: an open bracket, disposed toreleasably engage each of said channel, said open bracket allowingvertical adjustment of each of said channel; a bracket, disposed toreleasably engage said vertical post; a hinge, disposed to join saidopen bracket to said bracket, said hinge allowing horizontal adjustmentof each of said channel.
 4. The modular fence panel of claim 3, whereinsaid bracket is a closed bracket.
 5. A modular fence assembly,comprising: a plurality of horizontal channels arranged in mutuallyparallel relationship, each of said channels having a plurality ofthrough apertures positioned along the length of said channel, eachthrough aperture on a first channel being aligned to a correspondingthrough aperture on a second channel; a locking cap within each throughaperture, said locking cap being disposed to lock itself onto saidchannel upon insertion of said locking cap into said aperture, saidlocking cap also having a receptacle; a plurality of vertical hollowpickets arranged in a mutually parallel relationship, each of saidpickets extending through said locking cap in said through aperture oneach channel; a spring clip in each picket, said spring clip disposed tolock itself to said receptacle of said locking cap on a first channelupon insertion of said picket into said through aperture; a pair ofvertical posts, each vertical post being removably connected to one endof said channels; a connector connecting each of said vertical posts andone end of said channel, said connector being controllably moveable inboth horizontal and vertical directions.
 6. The modular fence assemblyof claim 5, wherein each of said locking cap is a four-sided plastichollow structure which fits snugly into said through aperture.
 7. Themodular fence assembly of claim 5, wherein said connector comprises anopen bracket and a closed bracket, joined by a hinge, said open brackethaving a slot on each side to provide vertical movement of said channel,said hinge providing horizontal movement between said open and closedbrackets.
 8. The modular fence assembly of claim 5, wherein said springclip in said picket is a V-shaped spring.
 9. The modular fence assemblyof claim 5, wherein said spring clip in said picket is a flattenedV-shape spring.
 10. A modular fence assembly, comprising: a plurality ofhorizontal channels, each of said channels having a plurality of equallyspaced-apart apertures along the length of each channel; locking meansfor locking to each of said aperture on the channels; a plurality ofvertical pickets, each picket having clip means within said picket forlocking said picket to said locking means on at least one of saidchannels upon inserting said picket through said locking means.
 11. Amodular fence assembly of claim 10, further comprising: a pair ofvertical posts; a plurality of connectors for connecting one end of eachchannel to one of said vertical posts.
 12. A modular fence assembly ofclaim 11, wherein each of said connectors comprises: a horizontalbracket for engaging one of said vertical post and said channel in ahorizontally adjustable position; a vertical bracket for engaging theother one of said vertical post and said channel in a verticallyadjustable position.
 13. A modular fence assembly of claim 10, whereinsaid locking cap means comprises: a cap with four sidewalls, surroundinga hollow through space; a one-way lock on one sidewall for allowing saidlocking cap to slide into said aperture and preventing said locking capfrom being removed; a receptacle on one sidewall for engaging said clipmeans from said picket.
 14. A method of assembling a modular fencepanel, comprising: providing upper and lower channels, preparing equallyspaced apart apertures on each channel; inserting a locking cap intoeach aperture, said locking cap locking itself to said channel uponinsertion; providing a vertical picket; inserting a spring clip intosaid hollow picket in a position to be engaged to said upper channel;inserting said picket into said upper and lower channel such that saidspring clip locks itself to said locking cap upon insertion.
 15. Themethod of claim 14, before said vertical picket is inserted into saidchannels, the method comprising: preparing a vertical post for each endof said channels; connecting said channel to said posting using aconnector, said connector allowing vertical adjustment and horizontaladjustment between said post and said channel.